PKN presents The Packaging Innovation Edit, a curated selection of standout global packaging innovations. Produced in collaboration with ThePackHub, this new monthly series highlights innovations advancing packaging design and function.
Cube-based tray system improves pallet efficiency for blueberries
AVI Global Plast, based in India, in collaboration with Smart Packaging Industries, has developed the Q-Bic packaging system, a redesigned rPET clamshell tray concept aimed at improving space utilisation and product protection in blueberry logistics.
The innovation reconfigures traditional punnet geometry by enabling individual trays to interlock and form cube-like structures once filled, reducing the empty space typically created by tapered clamshell designs. Conventional punnets are optimised for nesting when empty, but this shape leads to inefficient stacking and significant voids during transport.
The Q-Bic system allows multiple filled units to combine into compact cube formations that can be stacked more tightly within cartons. Trials indicate this approach can approximately double the number of packs per pallet, reducing unused space and lowering the volume required for refrigerated transport. It also contributes to material optimisation, with reported reductions of up to 59% in corrugated board used for secondary packaging in 125 g formats.
Structurally, the cube configuration distributes compression forces across multiple axes, reducing stress on individual pack lids and rims and potentially lowering the risk of fruit damage during transit. Integrated ventilation channels support airflow for cooling during storage and shipment.
ThePackHub’s View: The geometric redesign of clamshell trays offers a practical method for improving pallet density and reducing transport inefficiencies.
PKN's Comment: This is a smart example of design doing the heavy lifting. In a market where freight and cold chain costs are under pressure, improving pallet density without compromising product integrity is a commercially meaningful gain.
Supplier: AVI Global Plast, Smart Packaging Industries | Market: Food | Innovation type: New format, recycled materials | Substrate: PET, rPET
Paper bottle introduced for edible oil packaging
Littleseed, based in North Yorkshire, UK, has launched a rapeseed oil product packaged in a paper-based bottle developed by Frugalpac. The Frugal Bottle is composed of approximately 94% recycled paperboard combined with a food-grade internal liner to ensure compatibility with liquid food products.
The structure provides a barrier against light exposure, which can degrade oil quality, while also ensuring leak resistance and shelf stability. At 83 g, the bottle is significantly lighter than conventional glass alternatives, contributing to reduced transport-related emissions. The manufacturer reports a carbon footprint up to six times lower than glass bottles.
The bottle is also shatter-resistant, offering handling and distribution advantages. This marks the first use of the Frugal Bottle for rapeseed oil in the UK market, extending the format beyond wine and olive oil applications.
ThePackHub’s View: The use of a high paper-content bottle for edible oils demonstrates the potential for fibre-based formats to expand into liquid food applications traditionally dominated by glass or plastic.
PKN's Comment: Fibre-based bottles are moving beyond niche applications into mainstream categories. The real test now is whether supply chains and recycling systems can support scale without eroding the sustainability gains.
Brand: Littleseed | Supplier: Frugalpac | Market: Food | Innovation type: material substitution, lightweighting | Substrate: Paper, plastic
Metal applicator enhances skincare packaging with cooling functionality
Quadpack, headquartered in Barcelona, has introduced the Lotus Pod, a stainless steel applicator designed for use with its Skin-Up Bottle, expanding its range of application technologies beyond traditional flocked tips.
The applicator features an oval-shaped design with a central aperture that enables improved formula pick-up and controlled dispensing, particularly for thicker or hybrid formulations such as under-eye gels and serums. The use of stainless steel provides a cooling effect upon contact with the skin, supporting both functional and sensory benefits.
Paired with a cylindrical glass bottle, the system combines rigid packaging with a metal applicator component. The lotus leaf-inspired design includes a cavity to retain product, allowing users to dip and apply directly to targeted areas.
ThePackHub’s View: The introduction of a metal applicator adds a functional and sensory dimension to cosmetic packaging, particularly for formulations requiring controlled application.
PKN's Comment: In beauty, packaging is increasingly part of the product experience. Applicator-led design like this shows how brands can build differentiation and perceived value directly into the pack.
Supplier: Quadpack | Market: Health & Beauty | Innovation type: dosage control, user convenience | Substrate: Stainless steel
Refillable laundry system combines metal vessel and can refills
Ripl Efek, based in California, has introduced a refillable packaging system for laundry detergent that combines a durable stainless steel dispensing vessel with replaceable aluminium refill cans.
The system separates long-life and short-life components, with the primary container designed for repeated use and the refill format supplied in a 16 oz aluminium can. Refills are inserted directly into the vessel via a pull-tab opening, eliminating the need to pour liquid and reducing handling steps and potential product waste.
The vessel incorporates a silicone base, zinc dispensing spout, and a glass cap that doubles as a measuring cup. Aluminium was selected for the refill due to its barrier properties and recyclability, while each refill provides approximately 45 laundry loads.
ThePackHub’s View: The combination of a durable reusable vessel with insertable refill cans represents a structured approach to reducing single-use packaging while maintaining product integrity.
PKN's Comment: Refill models are evolving beyond flexible formats into more engineered systems. The question is whether consumers will trade simplicity for sustainability at scale – and at what price point.
Supplier: Ripl Efek | Market: Household | Innovation type: refill system, reuse model | Substrate: Aluminium, stainless steel
UV tag system enables tracking of plastic packaging waste streams
Kraft Heinz has partnered with UK-based technology company Polytag to implement a packaging tracking system using invisible ultraviolet tags. The initiative forms part of Polytag’s Ecotrace programme, designed to improve measurement of plastic packaging recyclability.
The system applies UV tags to single-use plastic packaging, allowing materials recovery facilities to detect and capture data at barcode level during sorting. This enables real-time insights into recycling rates, volumes processed, and waste stream pathways.
The rollout will initially focus on selected product lines, including Heinz Beanz and Heinz Tomato Ketchup, with packaging formats already designed to be fully recyclable. The pilot will assess effectiveness before potential expansion.
ThePackHub’s View: The integration of UV tag technology introduces a data-focused approach to packaging management, enabling more precise tracking of material flows within recycling systems.
PKN's Comment: Data is fast becoming the missing link in packaging circularity. Technologies like this could underpin future EPR schemes, particularly where verification of recycled content and recovery rates is under scrutiny.
Brand: Kraft Heinz | Supplier: Polytag | Market: Food | Innovation type: smart packaging, traceability | Substrate: Aluminium, Plastic
About ThePackHub:
ThePackHub is an internationally respected packaging innovation consultancy and essential resource hub for everything packaging. Founded in 2012 by CEO Paul Jenkins, the company is trusted by leading brands, retailers and packaging suppliers to turn complex challenges into actionable, forward-thinking solutions. At the core of ThePackHub’s offering is a commitment to equipping businesses with effective insights, strategies and innovations that reshape the way packaging is created and perceived. Its flagship Innovation Zone is a comprehensive, searchable database of global packaging innovation, valued by both the world’s largest companies and the most ambitious start-ups. ThePackHub is a community that plays an important role in connecting the packaging world through its events and initiatives, bringing together the brightest minds to share knowledge, spark innovation and drive the industry forward.
